Method for facing a single-faced corrugated web

ABSTRACT

Methods and apparatus are provided for adhering a plurality of discrete sheets sequentially to the open side of a single-faced corrugated web to produce a plurality of double-faced corrugated pieces of varying size, as desired, for the subsequent formation thereof into cartons or containers. Included herewith are means for separating the leading portion of the single-faced web after the initial adherence of the leading edge thereof with one of said discrete sheets for producing separate double-faced corrugated pieces with a single-faced overhang at each end thereof upon exit from the apparatus, and means causing the leading edge of the single-faced web to pick up and combine with the leading edge of one of said discrete sheets upon movement of the leading edge of said web through the nip of the combining rolls. Also included are means for momentary movement of a subsequently cut leading edge of the single-faced web away from the cutting station at the moment of severance of the foremost separated portion of said moving single-faced web to prevent jamming of the cut leading edge against the knives at the cutting station.

United States Patent [1 1 Gill [ METHOD FOR FACING A SINGLE-FACED CORRUGATED WEB [75] Inventor: Frank A. Gill, Stoughton, Mass.

[73] Assignee: David C. Dowd, Westboro, Mass. a

part interest [22] Filed: Nov. 26, 1971 [21] Appl. No.: 202,190

[52] US. Cl 156/205, 156/207, 156/250, 156/256, 156/281 [51] Int. Cl. B311 1/28 [58] Field of Search 156/205, 250, 210, 156/207, 263, 256, 264, 281, 519, 520; 271/50, 53, 60; 83/250, 251; 226/176, 177

[56] References Cited UNITED STATES PATENTS 3,306,805 2/1967 Klein et al. 156/210 2,513,093 6/1950 Hageman 226/176 3,307,995 3/1967 Martin, Sr..... 156/264 3,073,593 l/l963 Bauer 271/60 3,388,845 6/1968 Scully 83/250 Primary Examiner-Alfred L. Leavitt Assistant Examiner-F rank Frisenda, Jr. Attorney-J-lubcrt T. Mandeville et al.

[57] ABSTRACT Methods and apparatus are provided for adhering a plurality of discrete sheets sequentially to the open side of a single-faced corrugated web to produce a plurality of double-faced corrugated pieces of varying size, as desired, for the subsequent formation thereof into cartons or containers. Included herewith are means for separating the leading portion of the singlefaced web after the initial adherence of the leading edge thereof with one of said discrete sheets for producing separate double-faced corrugated pieces with a single-faced overhang at each end thereof upon exit from the apparatus, and means causing the leading edge of the single-faced web to pick up and combine with the leading edge of one of said discrete sheets upon movement of the leading edge of said web through the nip of the combining rolls. Also included are means for momentary movement of a subsequently cut leading edge of the single-faced web away from the cutting station at the moment of severance of the foremost separated portion of said moving singlefaced web to prevent jamming of the cut leading edge against the knives at the cutting station.

5 Claims, 5 Drawing Figures United States Patent [191 1 3,775,211 Gill [4s] Nov.27,1973

PATENTEDNUVZ'! I975 SHUT 1 [PF 4 FIG. 1

METHOD FOR FACING A SINGLE-FACED CORRUGATED WEB Generally speaking, this invention relates to methods and apparatus for facing the open-faced surface of a single-faced corrugated web. More particularly, this invention relates to methods and apparatus for applying sequentially a plurality of discrete sheets to the openfaced surface of a single-faced corrugated web, to produce upon exit from the apparatus a plurality of double-faced corrugated pieces of a desired size, having an overlapping of the applied single-facing on each end thereof without the need for any cutting or separation subsequently. Even more particularly, this invention relates'to the production of a plurality of double-faced corrugated pieces for subsequent formation thereof into so-called cardboard boxes, with one surface of the double-faced pieces having disposed thereon, a preprinted lithograph of desired identifying printing, pictures and other indicia, as desired.

As is well known, it has become increasingly important in recent years to produce corrugated cartons or containers of all sizes and shapes for the distribution of a variety of goods for sale, with the outer surfaces of those cartons having appropriate fine printing, pictures, etc. in the form of advertising slogans, in order to identify the contents of the carton. However, in order to produce such cartons in the past, the size of the cartons or containers was limited with respect to the extent of the printing on one surface thereof, to the dimensions (that is the circumference) of the printing press rolls if a continuous web of a printed facing sheet was to be combined with a single-faced corrugated web in a continuous manner. This was required because the printed material was printed continuously and sequentially along one face of the facing sheet for the singlefaced corrugated web.

in order to overcome this problem, a variety of methods and apparatus have been developed for producing discrete printed sheets individually of the desired size, which are subsequently applied in a sequential manner to the open-face of a single-faced corrugated web. One of these methods includes first adjoining the discrete printed sheets after the printing thereof into an elongated series of sheets, which are subsequently formed into a roll and then applied to the open-faced web.

Whereas, such methods and apparatus proved appropriate for overcoming the size and/or dimension problems previously encountered, and as noted above, such appropriate for combining the printed facing sheets to the single-faced web and producing the desired results at a cost making the product more desirable on a mass production basis, certain difficulties have arisen in the coordination between the registration of the printed sheets in combination with the single-faced web and the subsequent sequential cutting operations, so as not to cut the formed double-faced web in the middle of the printed design thereon. In addition, certain other difiiculties have arisen with the feeding apparatus for feeding the individual discrete printed sheets into the nip of the combining rolls for combining of these sheets onto the open-faced surface of the single-faced web, in that the feeding apparatus will sometimes fail to feed sheets in the appropriate desired sequence and therefore cause the subsequent cutting apparatus to cut into the center of the printed design.

Some of these difficulties noted above have been overcome by the development of a variety of positive feed type arrangements and complicated sequential control apparatus, so that the discrete printed sheets are fed by the utilization of a positive drive into the nip of the combining rolls, to be combined with the singlefaced corrugated web. These developments include the utilization of photocell arrangements for sequentially activating a positive feed, which in turn utilizes a complicated drive with a clutch and brake. Usually, with this form, the photocell reads preprinted marks on the discrete printed sheets.

Although these control arrangements have proved appropriate for producing the desired results, the cost of the complicated apparatus involved and the maintenance of such apparatus is such that the cost of the final product is affected to the point of making the product less than appropriate for certain mass production operations.

Thus, the problem arises that in order to produce the desired size double-faced corrugated pieces, having the appropriate fine printing or other indicia on one surface thereof, one must choose between methods and apparatus which produce such a product in a manner whereby there may be substantial wastage because of misalignment between the discrete printed sheets and the subsequent cutting apparatus, or selecting more expensive and complicated apparatus, which is expensive to maintain, for producing a more accurate product with little or no waste. With both choices, because of the problems noted, there is substantial increase in the cost of the final product.

This invention, by contrast, provides methods and apparatus for applying sequentially a plurality of discrete printed sheets to the open faced side of a single faced corrugated web, in a manner so that there is always appropriate alignment of the discrete sheets in the appropriate sequential manner along the longitudinal extent of the single-faced web, and with the combined laminate exiting from the combining rolls being in the form of individual pieces of the double-faced carton material having disposed on one surface thereof, the desired printed formation.

The above is achieved by the utilization of a controlled nip arrangement for the combining rolls, with a non-moveable gate or stop disposed in the nip thereof for engaging sequentially the leading edge of the foremost discrete printed sheets. Thereafter, upon approach of the leading edge of the single-faced web, one of the combining rolls moves in a manner whereby the leading edge of the foremost sheet moves into position for engagement of the bottom surface thereof with the leading edge of the single-faced web. This movement of one of the combining rolls also serves to change the size of the nip, so as to cause a gripping action between the printed sheet and the leading edge of the web moving through that nip.

A simple control for the movement of the combining roll adjusts the nip for different widths of corrugation for the single-faced corrugated web, and also provides for a slight adjustment so that the leading edge of the single-faced web does not engage the adjacent surface of the printed sheet until a point spaced from the leading edge thereof. This arrangement provides a final product in which the printed sheets are overlapping tne single-faced web on each end of the finally combined plurality of double-faced pieces. It should be understood that prior to this combining of the discrete single sheets with the single-faced web, that an adhesive is applied to the points of the corrugation of the single-faced web, so that after the initial combining in the combining rolls, the two joined parts are drawn together through the combining rolls.

Subsequent to this initial combining of the two pieces being joined, the following edge of the single-faced web which is to form a single, individual final piece, is cut from the rest of the moving single-faced web. This cutting or severing action takes place prior to the combining of the entire length of the single-faced web with the printed facing sheet, so that upon exiting of the combined pieces from the combining rolls, the desired individual double-faced pieces are already formed.

Also provided, in accordance herewith, are means for moving the newly formed leading edge of the continuously fed web away from the cutting station momentarily, so that the newly formed leading edge is not jammed against the cutting knives as they move across the axis of movement of the single-faced moving web. All of the above sequence of operations is controlled by a simple, adjustable cam arrangement for accommodating different lengths of printed sheets to be combined with the single-faced web, in order to produce finally different sizes of double-faced pieces, as desired, and depending upon the size and configuration of the printing on the individual discrete sheets to be applied to the single-faced web.

Accordingly, it is one object of this invention to provide methods and apparatus for applying a facing to the open faced side of a single-faced corrugated web. It is another object of this invention to provide methods and apparatus for applying discrete facing sheets sequentially along the open faced surface of a single-faced corrugated web in a manner whereby the sheets are always in proper register with the corrugated web portion of the final product.

It is a further object of this invention to provide a double-faced final product which is severed from the single-faced corrugated web when it exits from the compression rolls; and it is an additional object of this invention that no positive feed mechanism is required for feeding the discrete facing sheets to the compression rolls, and therefore, no synchronization is required between such feeding apparatus and the combining rolls or the web feeding speed.

With the foregoing and additional objects in view, this invention will now be described in more detail, and other objects and advantages thereof will be apparent from the following description, the accompanying drawings, and the appended claims.

Before describing this invention in more detail, it may be well to note that this invention has been found appropriate for use of a variety of different kinds and configurations of corrugations for the single-faced web, including E, B, C or A flute. This accommodation of a variety of corrugations, as well as sizes of printed facing sheets, is particularly appropriate for the arrangements in accordance herewith, because of the infinite variety of adjustments which can be made in the adjustable nip of the combining rolls, and because this simple, single adjustment not only accommodates different thicknesses of cormgated single-faced web, but also accommodates different lengths of overhang of the printed facing sheets in conjunction with the extent of length of the combined piece of single-faced web adhered to a particular printed facing sheet.

In the drawings:

FIG. 1 is a side elevational view of apparatus embodying and for practicing this invention;

FIG. 2 is a sectional side elevational view of FIG. 1, having certain parts removed for clarity, and showing parts in different positions of movement;

FIG. 3 is an additional sectional side elevational view of FIG. 1, with certain parts removed for clarity, and showing parts in an additional point of movement in the sequence of operations of apparatus embodying this invention;

FIG. 4 is a sectional view along lines 44 of FIG. 2; and,

FIG. 5 is a longitudinal sectional view of a doublefaced corrugated piece of material produced, in accordance herewith.

Referring to the drawings in which like reference characters refer to like parts throughout several views thereof, FIG. 1 shows a combiner or laminator generally designated as 10, having an upright supporting structure 12, supported on a base 14. It is to be understood that this is a side elevational view and a like side will be disposed on the opposite side of the'apparatus in mirror image fashion.

Joumaled for rotation in the upright supporting structure 12 is a drive shaft 100, having a drive roll 18 disposed thereon. Drive shaft is driven by main drive motor 16, through a chain drive connection, all in well known manner, and not shown because it does not form any part of this invention. Shown in the lower left-hand corner of FIG. 1 is an entering, continuously moving supply of single-faced corrugated web 20, moving in the direction of arrow 11.

The supply of single-faced web may be from any wellknown source, such as a plurality of supply rolls of such single-faced web, or a separate single-faced web producing station, including a supply of the single-facing and a supply of the material to be corrugated, together with a corrugating station and an adhesive station for joining the single-face to the corrugated portion of the single-faced web, all in well known manner.

Web 20 proceeds around guide rolls 22 and 24, and thereafter upwardly and around pressure roll 26, which in connection with drive roll 18, serves to draw the web 20 through the apparatus. As can be seen in FIG. 1, shaft 25 of pressure roll 26 is joumaled for rotation at one end of lever 28, which is pivoted at 30 to a supporting bracket 32. The opposite end of lever 28 is pivotly connected at 34 to piston rod 36 of a reversible fluid operated cylinder 38. In the position shown in FIG. 1, the piston rod of cylinder 38 is in its extended position to force pressure roll 26 into an engaging position with drive roll 18, in order to draw the single-faced web 20 through the nip formed therebetween.

If for some reason it becomes necessary to release the drive of the web through the apparatus, the operator can move the valve, not shown, controlling cylinder 38 for changing the direction of compressed air feed against the faces of the piston in cylinder 38 for moving piston rod 36 to the left, and moving pressure roll 26 away from pressure engagement with the surface of drive roll 18. With such a movement, the driving of the single-faced web 20 through the apparatus ceases.

Disposed midway in the apparatus are cooperating shearing blades 40 and 42, for shearing web 20, in an appropriate sequence of operations which will be described below. Shearing blade 40 is stationary but can be adjusted from right to left, as shown in FIG. 1, for accommodating different widths of web 20. Blade 42, on the other hand, is slideable into shearing action with blade 40. This is accomplished by the action of arm 46, pivoted at one end at 48, and slidingly pivoted at the other end at 44, connecting to the sliding blade 42. Disposed in the middle of arm 46 is cam follower 43, which engages the surface of cam 50, joumaled on shaft 57.

Disposed in the left-hand side of FIG. 1 is blade drive motor 52, having drive shaft 53, with drive pulley 54 disposed thereon. Pulley 54, is in turn drivingly connected to pulley 58, joumaled on shaft 60, by drive belt 56. Also joumaled on shaft 60 is gear 51 in driving engagement with gear 53, journaled on shaft 57. Also joumaled on shaft 60 is blade drive clutch 62, having an abutment which engages a clutch-engaging bar 70, pivoted at 72, for movement in and out of engagement with clutch 62 under the action of shaft 66 of solenoid 64. Disposed between bar 70 and shaft 66 is a spring 68 for resiliently holding bar 70 into engagement with clutch 62. The action of solenoid 64 is controlled by switch 126, the movement of which will be described below.

Slidingly disposed on upright supporting structure 12 is an adhesive unit, designated generally at 74. Adhesive unit 74 is moveable from the right to the left, in relationship to supporting structure 12, under the control of an adjusting wheel 82, which controls the pressure of applicator roll 98 against web 20, and the width of nip 99 between applicator roll 98 and vacuum roll 110. Rigidly connected to the upright supporting structure 76 of adhesive unit 74 is a bracket 80, which is in turn rigidly connected to a pressure cylinder 78. By controlling the direction of fluid to either end of the piston in cylinder 78, glue unit 74 can be released from contact with web 20 at any time by the operator, so as to eliminate application of an adhesive material to web 20 if the entire unit should fail in operating for some reason.

Supported in adhesive unit 74, is an adhesive tray 77, containing adhesive 79 for application to web 20. Journaled for rotation in supporting structure 88 is shaft 86, having a metering roll 84 disposed thereon. Metering roll 84 rotates in adhesive 79 for picking up and applying adhesive to applicator roll 98 in a metered amount, all in well known fashion. Connected to metering roll 84 is variable speed drive motor 94 for driving the metering roll together with applicator roll 98, at a variety of speeds, as desired, and all in well known fashion.

Rigidly connected to supporting bracket 88 for metering roll 84 is an adjusting shaft 92, having screw adjustment 90 connected thereto, for adjusting the depth of metering roll 84 in adhesive 79, for adjusting the amount of adhesive picked up from tray 77 by metering roll 84. Also connected to bracket 88 is reversible pressure cylinder 96, the control of which will cause with drawal of metering roll 84 from contact with adhesive 79, contained in adhesive tray 78. As can be seen in FIG. ll, upwardly moving web 20 is engaged in nip 99 between applicator roll 98 and vacuum roll for application of adhesive to the points of the corrugations of web 20, immediately prior to web 20 being carried around vacuum roll 110.

Journaled on drive shaft 180 is pulley 102,. which drives a pulley 106, joumaled on shaft 108 of vacuum roll 110, through the action of drive belt 104. Gear 112 is, in turn, joumaled on shaft 108, which gear 112 is in engagement with a gear 114, joumaled on shaft 111. Also joumaled on shaft 111 are a plurality of change gears 115, for engagement with a gear 116, joumaled on shaft 1 18. The change gears 115 can be adjusted for different speed engagement in differing ratios with gear 116, for driving shaft 1 18 at different speeds. Also journaled on shaft 118 are cams 120 and 124, for operating switches 122 and 126, the operation of which will be described below. Non-moveable combining roll 128 is shown in FIG. 1, which combining roll 128 is driven through a pulley arrangement with a pulley disposed on shaft 108 of vacuum roll 110, with this pulley arrangement not being shown, for clarity, because it does not form any part of the invention herein.

Disposed immediately above non-moveable combining roll 128 is a plurality of moveable rolls 130, which are disposed transversely across the extent and above non-moveable roll 128, as shown in FIG. 4. A feed table 142 is shown, arranged for feeding individual facing sheets, which are fed to nip 152 (FIG. 2) between combining rolls 128 and 130.

Also shown in FIG. 1 is a non-moveable stop 136, for engaging the leading edges of sheets momentarily fed to and into nip 152. As can be seen in FIG. 1, the sheets are fed in overlapping fashion, with sheet 138 already partially joined to web 20 and moving under the bottom surface 185 of rigid stop 136, whereas the next succeeding sheet has been moved against the nonmoveable stop 136 for subsequent joining with web 20 in the sequence, in accordance herewith, and as described below. Moveable combining rolls 130 are journaled on shafts 133, which in turn are joumaled on moveable arms 132 (FIG. 4), which is pivoted at the opposite end thereof on supporting rod 137. Arms 132 are pivoted on shaft 137 by the action of reversible fluid pressure cylinder 134, the control of which will be described below. The piston rod for cylinder 134 engages a cross brace, not shown, interconnecting arms 132.

As can best be seen in FIG. 2, an upwardly extending arm is rigidly connected at substantially right angles to at least one moveable pivot arm 132, with am 145 having contact pressure adjusting screw 146 disposed thereon. Screw 146 engages stop 1 for controlling the extent of downward movement of moveable arm 132 and compression rolls 130. It is within the purview of this invention that adjusting screw 146 can be adjusted for controlling the width of nip 152 between rolls 128 and 130, for accommodating different widths of single-faced web passing through, for joining with the individual sheets being fed by table 142. Also, this adjustment is such so as to control the point of engagement of the leading edge of web 20 with the bottom surface of the leading edge of the sheet being joined thereto at nip 152, so that there is a slight overhang produced, if desired, during the joining procedure of the leading edge of the sheet with respect to the leading edge of the single-faced web.

Disposed internally of vacuum roll 110 is a nonrotating baffle 146, which baffle is foraminous in area 148 for controlled application of vacuum only in area 148, only around approximately one-quarter of the circumference of vacuum roll 110, as shown in FIG. 2.

As a further feature of this invention, an arrangement is shown in FIG. 2 for preventing jamming of the leading edge of web below shearing blades 40-42 at the moment of severing action. It should be understood that during the operation of the apparatus, in accordance herewith, the single-faced web 20 is being fed continuously through the apparatus. Thus, during the moment when the shearing blades join for severing the leading portion of the web being joined to a sheet at nip 152, there would be a jamming action of the newly formed leading edge of the web below shearing blades 40-42.

In order to accommodate the continuous movement of web 20, therefore, a loop control pan 156 is arranged to carry the opposed arcuate surface 158 opposite the surface of feed roll 18. Loop control pan 156 is supported for vertical movement on bracket 163, connected at 162 to loop control pan 156. Bracket 163, is in turn connected to the piston rod 164 of a pressure fluid reversible control cylinder 166, which is operated through the action of valve 172 through lines 168 and 170, directed to each face of the piston in control cylinder 166. Valve 172, is in turn controlled by the action of plunger 174, having a cam follower 176 attached thereto, which cam follower 176 follows the surface of cam 178, joumaled on shaft 60. As can be seen in FIG. 3, when the raised portion of cam 178 moves into contact with cam follower 176, valve 172 operates to activate control cylinder 166 to lower loop control pan 156 momentarily when moveable shearing blade 42 moves into engagement with stationary blade 40. Thus, the entire longitudinal extent of web 20 following arcuate surface 158 opposite feed roll 18 and the upper extension 160 thereof is moved slightly downward so that the severed new leading edge 180 of web 20 is moved away from the vicinity of engaging blades 40-42.

With regard to feed table 142, sheets may be fed therealong by hand or by any appropriate mechanical feeding apparatus, the only limitation being that the sheets be fed in overlapping fashion, so that after a joined sheet is being drawn around the bottom edge of permanent stop 136 (such as sheet 140 in FIG. 3), another sheet moves against the pennanent stop 136 for subsequent joining in nip 152, with a subsequent portion of web 20, such as sheet 181 in FIG. 3.

Angled support 187 (FIG. 1) connected to the end of feed table 142 at 201, serves to support moveable compression rolls 130. In this connection, shaft 137 is journaled in a pair of braces 203 at each end of compression rolls 130, which braces 203 are connected to support 187.

Adhesive 79 used may be of any composition known in the art, including a thermosetting adhesive requiring subsequent heat setting, after exiting from the apparatus at nip 152, in accordance herewith. However, it has been found appropriate, in accordance herewith, to utilize a cold resin adhesive, eliminating the necessity for subsequent heat application.

edge of web 20. During this procedure, reversible fluid cylinder 38 is actuated to move the piston rod 36 thereof to the left in FIG. 1, so as to move pressure roll 26 away from engagement with drive roll 18. Thus, the leading edge of web 20 may be fed through and threaded between the nip of rolls 18 and 26, and into the area between the surface of drive roll 18 and arcuate surface 158 of loop control pan 156.

Thereafter, cylinder 38 is actuated to move pressure roll 26 to the position shown in FIG. 1, for pressure engagement of the web 20 in the nip between rolls [8 and 26. This action begins the continuous driving movement of the web 20 through the apparatus, around roll 18 and upwardly through the open blades 40-42, and into nip 99 formed between rolls 98 and l 10. It should be understood that at this point, controls 82 and will be adjusted according to the type of web 20 passing through the apparatus to control the width of the nip between rolls 98 and 110, as well as the extent of movement of metering roll 84 into adhesive 79 contained in tray 78. Also, the speed of motor 94 will be adjusted to accommodate the appropriate amount of adhesive applied by metering roll 84 to applicator roll 98, which in turn applies the adhesive to the points of the corrugations of web 20, all in well known fashion.

As web 20 enters nip 99, the open face side of web 20 is applied with adhesive simultaneously with the surfaced side thereof coming into engagement with the vacuum engaging portion 148 of vacuum roll 110. Thus, web 20 is carried partially around the extent of vacuum roll until it comes into engagement with supporting surface 150, whereupon the web follows surface 150 toward nip 152, as shown in FIG. 2.

As shown in FIG. 1, upper compacting rolls 130 are in their raised position and the leading portion of web 20 has been partially joined with a sheet 138, the rear portion of which is being pulled from feed table 142 around the lower edge 185 of permanent stop 136, while the leading edge of the next succeeding sheet 140 is held stopped against the surface of permanent stop 136. In FIG. 2, a finished outgoing product 144 is shown with the sheet 138 permanently affixed to the open faced surface thereof.

At this point, cam has come into engagement with the follower for switch 122 (FIG. 1), for activating reversible cylinder 134, for moving upper compression rolls downwardly to form the adjusted nip 152. In this connection, and as noted above, adjusting screw 146 has come into engagement with stop 148, for limiting the downard movement of upper compression rolls 130. This downward movement of the compression rolls 130 serves to move the leading edge of sheet (FIG. 2) downwardly, out of engagement with permanent stop 136, and to form the width of nip 152 according to the adjustment previously made of adjusting screw 146. Thus, when the severed leading edge of web 20 moves into nip 152, the initial corrugation points of the open face side of web 20 engage sheet 140 in nip 152, slightly behind the leading edge thereof, and continuous movement of the web 20 serves to pull sheet 140 off feed table 142 and simultaneously combine sheet 140 with web 20.

Thereafter, further continuous movement of web 20 through nip 152 carries the sheet 140 therealong, as

shown in FIG. 3. In the meantime, cam 120 has moved out of engagement with the follower for switch 122, and causes cylinder 134 to be actuated for raising the upper compression rolls 130 away from nip 152. Thus, as can be seen in FIG. 3, sheet 140 is being continuously drawn through nip 152, while the compression rolls 130, in their raised position, allow the next succeeding sheet 181 to come to rest against permanent stop 136.

While this action is taking place, cam 124 has moved into engagement with the follower of switch 126. Switch 126 serves to operate solenoid 64 for moving clutch bar 70 downwardly out of engagement with clutch 62, which in turn allows the rotation of gear 51 on shaft 60, engaging gear 53 on shaft 57. The rotation of shaft 57 in turn causes the rotation of cam 50, which rotates so that the higher portion thereof engages cam follower 43 on arm 46, for moving arm 46 and blade 42 to the right to shear web 20. The position of the shearing blades 40-42 at this instant are shown in FIG. 3. With this arrangement, the leading portion of web will be joined with sheet 140 to form a single separated two-sided product upon exiting from nip 152. In this connection, it should be understood that permanent stop 136 is arranged so that the lower surfacethereof is spaced from the surface of lower compression roll 128 to an extent causing the sheet, such as l40in FIG. 3, to follow a path which will cause the sheet to come into engagement with the adhesively applied points of the open face of web 20 passing through nip 152.

Simultaneously with the shearing action of blades 40-42, and the rotation of shaft 60 for carrying out this function, the rotation of shaft 60 also serves to rotate cam 178, as shown in FIG. 3, so that the wide portion thereof comes into contact with cam follower 176 of valve 172. Thus, simultaneously with the shearing action of blades 40-42, cylinder 166 will be actuated to move loop control pan 156 downwardly, to move the newly severed leading edge 180 of web 20 below cooperating shearing blades 40-42 and out of an engagement with those blades, momentarily.

Thereafter, cam 124 (FIG. I) will move out of engagement with the cam follower of switch 126, for causing blade clutch bar 70 to move back into engagement with clutch 60 and stop rotation of gear 51 and cooperating gear 53, after the wide portion of cam 50 has passed follower 43 and moved blade 42 back to the left, as shown in FIG. 1. Simultaneously, the wide portion of cam 178 will have passed follower 176, causing plunger 164 of control valve 172 to move upwardly and cause cylinder 166 to move its piston and associated rod 164 upwardly, to move loop control pan 156 back into the position shown in FIG. 2.

It should be understood, that during this entire sequence the web 20 is continuing to be fed between the nip formed between rolls 26 and 18. After this sequence, leading edge 180, as shown in FIG. 3, will be continuously fed upwardly toward trip 99, for subsequent engagement of further portions of web 2.0, with succeeding sheets being fed from table 142 into nip 152, It should be understood that, in accordance herewith, the adjusting screw 146 is so adjusted to provide that the leading edge of the web 20 engages the lower surface of a sheet in nip 152, slightly behind the leading edge thereof, in order to provide an overlap 141 (as shown in FIG. 3).

Further, the adjustments of the change gears are arranged, in accordance herewith, so that the web is severed after joining with the sheet, to provide a severed length of web, which is slightly less than the length of the sheet being joined thereto, so that there is an overhang of the sheet at the rear edge of the produced product as well. Thus, as shown in FIG. 5, a finished product 182 has a sheet disposed on one surface thereof with sheet 140 having overhangs 1411 at each end thereof. This arrangement is particularly appropriate for subsequent formation of the product obtained, in accordance herewith, into cartons or containers because the corrugated portion thereof does not have to be cut in order to conform with the sheet applied thereto, thus eliminating a substantial amount of wastage. As can be seen in FIG. 4, the plurality of upper compression rolls 130 are moveable into cutout portions 205 of the permanent stop 1136. Upon movement of the pivoted arms 132 downwardly, the arms (one arm at each side of each roller 132) moves the shafts 133, carrying the plurality of upper compression rollers 130 downwardly below the lower surface of the stop 136, for moving the leading edge of a sheet downwardly and under the bottom edge 185 and into engagement with the leading edge of the web 20, passing into nip 152. v

The various lines for controlling the pressure cylinders herein are not shown for purposes of clarity since they do not form any part of the invention herein. It should be understood that the cylinders may be hydraulic or pneumatic, as desired, but preferably are pneumatically driven. Also, electrical controls may be used. The power source for the cylinders may be from any well known source such as a compressor for a pneumatic system, all in well known manner.

Thus, it can be seen with the arrangements, in accordance herewith, that a plurality of discrete sheets having fine lithographic printing and designs thereon, may be applied sequentially to a continuously moving web of single-faced corrugated material in a manner whereby the final product, upon exiting from the combining apparatus, is a completely separated two-faced corrugated piece having on one surface thereof the appropriate and desired fine printing and design, and without the necessity of any further severing procedures. With such an arrangement, the sheets are always effectively aligned with. the associated piece of the single-faced web joined with those sheets, and in a manner to provide appropriate and desired overhangs at each end of the combined product exiting from the machine. In addition, because of the unique loop control pan arrangement herein, there is no jamming of the severed leading edge of the web, even though it is continuously being fed at the point of severance prior to the severing blades withdrawing from the path of movement of the continuously fed web.

Also, because of the controlled nip arrangement of the combining rolls herein, no special provisions have to be made for coordinating the feeding of the discrete printed sheets in relationship to the movement of the web through the nip, since each succeeding leading edge of web serves to make contact with the lower surface of the sheet already stationed at the nip. Furthermore, because of this particular adjustable nip arrangement, a power feed to the nip of the discrete printed sheets is unnecessary. As noted above, the apparatus herein accommodates both hand feeding and mechanical feeding, as desired.

Furthermore, the adjustments for accommodating different lengths of sheet are extremely simple, requiring only an adjustment of the change gears in order to change the sequence of cams 120 and 124 for controlling the switches 122 and 126, and the adjustment screw 146 for controlling the adjustable nip 152, as desired. The only further adjustments required in addition to this, are the usual adjustments of the metering roll and the pressure applied by the applicator roll at nip 99.

Accordingly, the methods and apparatus, in accordance herewith, serve to laminate an appropriate lithographic preprinted, precut sheet to a single-faced corrugated web, preferably by the use of a cold resin adhesive. Because of the use of the sequence of cutting the single-face web portion prior to its complete combination with the individual sheets, the apparatus herein provides a modular type construction, permitting an extremely compact design requiring a minimum of space. In addition, the arrangements herein accommodate a variety of different size flute configurations and a variety of different sized printed sheets.

The products obtained, in accordance herewith, may be formed into containers having life-like images, enhancing the merchandising of the products contained therein, which containers are particularly appropriate for point-of-purchase products, such as toys, games, small household appliances, cosmetics and gift items. This is achieved simultaneously with a substantial reduction in cost of such containers, because of the substantial reduction in wastage achieved with the precise registration brought about with the methods and apparatus herein. Furthermore, because of the utilization of continuous web feeding, a larger quantity of product is produced over a period of time than with the prior art devices requiring intermittent feeding, all of which make the arrangements herein highly advantageous commercially.

While the methods and apparatus herein described constitute preferred embodiments of the invention, it is to be understood that the invention is not limited to these precise methods and apparatus, and that changes may be made therein without departing from the scope of the invention, which is defined in the appended claims.

What is claimed is:

1. In a method for adhesively combining sequentially a plurality of discrete sheets along one surface of a continuously moving web, in a combining nip with a source of continuously moving web for feeding to said nip, and a source of overlapped discrete sheets sequentially fed to said nip; the steps which comprise moving said sheets sequentially into said nip and against a rigid stop disposed therein; adjusting the said nip from a first position in which said nip is wider than the thickness of the combined sheets and web to a second position in which said nip is adjustably spaced for combining said sheets and said web together, said adjusting step moving the leading edge of the foremost of said discrete sheets below the bottom surface of said rigid stop; engaging the bottom surface of the said leading edge of said discrete sheet below said stop with the leading edge of said discrete web; combining at least a portion of said discrete sheet with a portion of said continuously moving web; readjusting the width of said nip from said second position back to said first position while said combining step is continuously being carried out; severing a portion of said continuously moving web at a point prior to said nip, said severed portion of said web being of desired length to combine with said discrete sheet, said combining step continuing to be carried out during said severing step, removing the combined severed product from said nip; and repeating said sequence of steps continuously for forming a plurality of combined severed products.

2. A method as described in claim 1, in which said second position of said nip is adjusted to provide for engagement by the leading edge of said continuously moving web with the bottom surface of said leading discrete sheet at a point spaced from the leading edge thereof.

3. A method as described in claim 1, which includes the step of applying adhesive to the combining surface of said web prior to the entry thereof into said nip.

4. A method as described in claim 1, which includes the additional step of moving at least a portion of the severed leading edge of said web away from the point of severance momentarily, in a direction opposite its direction of travel during said severing step.

5. A method as recited in claim 1, in which said continuously moving web is a single-faced corrugated web; said discrete sheets have printed lithographs disposed on one side thereof; and said combining step is carried out by applying the nomprinted side of said sheets to the open faced side of said single-faced web. 

1. In a method for adhesively combining sequentially a plurality of discrete sheets along one surface of a continuously moving web, in a combining nip with a source of continuously moving web for feeding to said nip, and a source of overlapped discrete sheets sequentially fed to said nip; the steps which comprise moving said sheets sequentially into said nip and against a rigid stop disposed therein; adjusting the said nip from a first position in which said nip is wider than the thickness of the combined sheets and web to a second position in which said nip is adjustably spaced for combining said sheets and said web together, said adjusting step moving the leading edge of the foremost of said discrete sheets below the bottom surface of said rigid stop; engaging the bottom surface of the said leading edge of said discrete sheet below said stop with the leading edge of said discrete web; combining at least a portion of said discrete sheet with a portion of said continuously moving web; readjusting the width of said nip from said second position back to said first position while said combining step is continuously being carried out; severing a portion of said continuously moving web at a point prior to said nip, said severed portion of said web being of desired length to combine with said discrete sheet, said combining step continuing to be carried out during said severing step, removing the combined severed product from said nip; and repeating said sequence of steps continuously for forming a plurality of combined severed products.
 2. A method as described in claim 1, in which said second position of said nip is adjusted to provide for engagement by the leading edge of said continuously moving web with the bottom surface of said leading discrete sheet at a point spaced from the leading edge thereof.
 3. A method as described in claim 1, which includes the step of applying adhesive to the combining surface of said web prior to the entry thereof into said nip.
 4. A method as described in claim 1, which includes the additional step of moving at least a portion of the severed leading edge of said web away from the point of severance momentarily, in a direction opposite its direction of travel during said severing step.
 5. A method as recited in claim 1, in which said continuously moving web is a single-faced corrugated web; said discrete sheets have printed lithographs disposed on one side thereof; and said combining step is carried out by applying the non-printed side of said sheets to the open faced side of said single-faced web. 